Abstract

Polymers are one of the most commonly used materials in engineering applications (such as structure, pipelines, etc.). Infield practices, whenever a crack/leakage develops in polymeric pipelines, there is need of quick online repair/maintenance. In such cases, replacement of the whole pipeline section can lead to high downtime and cost. The online repair/maintenance of those cracks/leakages can be performed with the application of friction/friction stir welding but it needs the development of polymeric composite material that is compatible with substrate (pipeline) materials. This study outlines the development of such polymeric composites on the basis of maintaining rheological properties. In this chapter, an experimental investigations have been reported for two differently characterized polymers (namely, acrylonitrile butadiene styrene (ABS) polyamide (PA)6), which were reinforced with Al metal powder by twin screw extrusion process. The results suggested that ABS reinforced with 15% Al metal powder by weight (ABS–15Al) and PA6 with 50% Al (PA6–50Al) resulted in similar range of melt flow index (MFI) as 11.57 g/10 min and 11.97 g/10 min, respectively, and confirmed the compatibility for joining of both polymer by friction/friction stir welding. The functional prototypes have been printed on commercial fused deposition modeling (FDM)-based 3D printer, (by using feedstock filament prepared with standard twin screw extrusion process). The mechanical properties of composite feedstock filaments were investigated for optimization of extrusion parameters. Additionally, friction stir welding has been performed to check the feasibility of joining of developed composite parts (prepared as functional prototypes) on FDM.

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